Sealing gussets together through apertures in multi-wall paper and woven polypropylene packages or bags

ABSTRACT

Reclosable gusseted packages or bags have improved resistance to leaking or spilling through the gussets by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets in the package or bag, or by sewing the gussets shut in areas proximate to the zipper.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to improving the leak-proof or spill-resistant quality of gussets in reclosable packages, particularly those made with multi-wall paper or woven polypropylene. This is achieved by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets, or by sewing the gusset shut.

2. Description of the Prior Art

In the prior art of reclosable packages or bags, it is well known to use gussets between the front and rear walls to increase the capacity of the package or bag with only a small increase in the packaging material, such as multi-wall paper or polypropylene.

However, the use of gussets can increase the tendency for the contents of the reclosable package or bag to leak from the gusset area proximate to the intersection of the package or bag walls and the zipper. More specifically, the contents can travel up the center of the package or bag, between the zipper profiles and out the gusset.

OBJECTS AND SUMMARY OF THE INVENTION

It is therefore an object of the present invention to eliminate or reduce the leakage of contents of a gusseted reclosable package or bag through the gussets proximate to the intersection of the zipper profiles and the package or bag walls.

This and other objects are attained by sealing the gussets together through apertures in the gusset walls, by sealing the zipper flanges together through apertures passing through the gussets, or by sewing the gussets shut in areas proximate to the zipper.

DESCRIPTION OF THE DRAWINGS

Further objects and advantages of the invention will become apparent from the following description and claims, and from the accompanying drawings, wherein:

FIG. 1 is a plan view, partially in phantom, of a prior art gusseted package or bag, showing the route through which contents may inadvertently escape.

FIG. 2 is a cross-sectional view along plane 2-2 of FIG. 1.

FIG. 3 is a cross-sectional view along plane 3-3 of FIG. 1.

FIG. 4 is a perspective view of the expanded walls of the package or bag of the first embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 5 is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the first embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 6 is a plan view, partially in phantom, of the package or bag of the first embodiment of the present invention after installation of the reclosable zipper. This plan view is likewise applicable to the second embodiment of the present invention.

FIG. 7 is a perspective view, partially in phantom, of the expanded walls of the package or bag of the second embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 8 is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the second embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 9 is a perspective view of the expanded walls of the package or bag of the third embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 10 is a perspective view, partially in phantom, of the collapsed walls of the package or bag of the third embodiment of the present invention prior to the installation of the reclosable zipper.

FIG. 11 is a plan view, partially in phantom, of the package or bag of the third embodiment of the present invention after installation of the reclosable zipper.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings in detail wherein like numerals indicate like elements throughout the several views, one sees that FIG. 1 is a plan view, partially in phantom, of a prior art reclosable package or bag 100 and that FIGS. 2 and 3 are cross-sectional views thereof. The package or bag 100 is formed from co-extensive front wall 102 and rear wall 104 which are typically formed from polymeric materials (such as, but not limited to, polyethylene or polypropylene, including woven polypropylene), multi-wall paper or laminates. Gussets 106, 108 (illustrated in phantom in FIG. 1 and in cross section in FIG. 2) are formed as inwardly pointing folds between the side edges of front and rear walls 102, 104, typically integral with, or at least of the same material as, front and rear walls 102, 104. Gusset 106 is formed from gusset walls 106 a, 106 b in an inwardly pointing V-shaped configuration while gusset 108 is formed from gusset walls 108 a, 108 b in an inwardly pointing V-shaped configuration. The bottom edges of front and rear walls 102, 104 are sealed or otherwise closed or joined to form bottom 110. Mouth 112 is formed between the top edges of front and rear walls 102, 104. Zipper assembly 200 is sealed, glued or otherwise secured to the upper exterior of front and rear walls 102, 104. As shown best in FIG. 3, zipper assembly 200 includes first profile 202 and second profile 204. First profile 202 includes first interlocking element 206 and first flange 210. Second profile 204 includes second interlocking element 208 and second flange 212. First and second flanges 210, 212 are sealed, glue or otherwise secured to the upper exterior of front and rear walls 102, 104, respectively. Typically, zipper assembly 200 includes slider 214 mounted on first and second profiles 202, 204. Slider 214 operates in a conventional manner of interlocking first and second interlocking elements 206, 208 with each other when moved in a first direction and separating first and second interlocking elements 206, 208 when moved in a second direction. However, alternatively, first and second interlocking elements 206, 208 may have a “press-to-close” configuration in which no slider is required.

As shown by the circuitous path indicated by the arrow in FIG. 1, this design is susceptible to contents within package or bag 100 traveling up the center of the package or bag 100, between the first and second flanges 210, 212 and out the gussets 106, 108. This leakage or spillage is illustrated for the first gusset 106 but is equally applicable to the second gusset 108.

This deficiency can be minimized or eliminated by closing the gussets 106, 108 proximate to the zipper assembly 200 as illustrated in the embodiments of the present invention.

FIG. 4 illustrates a first embodiment of the present invention wherein apertures 120, 122, 130, 132 are formed in gusset walls, 106 a, 106 b, 108, 108 b, respectively. When the gussets 106, 108 are collapsed as shown in FIG. 5, apertures 120, 122 align with each other so that a portion of front wall 102 contacts a portion of rear wall 104 through the aligned apertures 120, 122. Similarly, apertures 130, 132 align with each other so that a portion of front wall 102 contacts a portion of rear wall 104 through the aligned apertures 130, 132. When the first and second flanges 210, 212 of zipper assembly 200 are placed over front and rear walls 102, 104 and sealed thereto, front wall 102 is sealed to rear wall 104 through aligned apertures 120, 122 and through aligned apertures 130, 132 thereby closing the upper ends of the gussets 106, 108 and eliminating or reducing the spillage described above. The sealing can be heat sealing by ultrasonic or conduction, or can be by adhesive. Alternatively, grommets (not shown) can pass through aligned apertures 120, 122 and 130, 132. The resulting package or bag 100 is illustrated in FIG. 6. The parenthetical notations to numerals 118, 124, 128, 134 apply to the extent that FIG. 6 likewise illustrates the second embodiment of the present invention.

FIG. 7 illustrates a second embodiment of the present invention wherein apertures 118, 124 (in phantom) are formed in front and rear walls 102, 104 respectively, so as to align with apertures 120, 122. Likewise, apertures 128, 134 are formed in front and rear walls 102, 104, respectively so as to align with apertures 130, 132. When the gussets 106, 108 are collapsed as shown in FIG. 8, apertures 118, 120, 122, 124 align with each other. Similarly, apertures 128, 130, 132, 134 align with each other. When the first and second flanges 210, 212 of zipper assembly 200 are placed over front and rear walls 102, 104 and sealed thereto, portions of first flange 210 are sealed to portions of second flange 212 through aligned apertures 118, 120, 122, 124 and through aligned apertures 128, 130, 132, 134 thereby closing the upper ends of the gussets 106, 108 and eliminating or reducing the spillage described above. The resulting package or bag 100 is illustrated in FIG. 6, as is the first previously described first embodiment. Alternatively, grommets (not shown) can pass through aligned apertures 118, 120, 122, 124 and 128, 130, 132, 134.

FIGS. 9 and 10 illustrate a third embodiment of the present invention wherein thread or similar material is used to form first and second stitches 150, 152. First stitch 150 stitches together gusset walls 106 a, 106 b with the portions of front and rear walls 102, 104 which contact the gusset walls 106 a, 106 b. Likewise, second stitch 152 stitches together gusset walls 108 a, 108 b with the portions of front and rear walls 102, 104 which contact the gusset walls 108 a, 108 b. Stitches 150, 152 close the upper ends of the gussets 106, 108 thereby eliminating or reducing the leakage described above. As shown in phantom in FIG. 11, typically, stitches 150, 152 are formed in an area of front and rear walls 102, 104 which is covered by the zipper flanges 210, 212.

Thus the several aforementioned objects and advantages are most effectively attained. Although preferred embodiments of the invention have been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. 

1. A reclosable package or bag comprising: a front wall and a rear wall; a first gusset formed between a first edge of the front wall and a first edge of the rear wall, the first gusset including a first front gusset wall and a first rear gusset wall; a second gusset formed between a second edge of the front wall and a second edge of the rear wall, the second gusset including a second front gusset wall and a second rear gusset wall; a mouth formed between a top edge of the front wall and a top edge of the rear wall; a reclosable zipper secured to the front and rear walls proximate to the mouth; and wherein the first front gusset wall includes a first front gusset wall aperture and the first rear gusset wall includes a first rear gusset wall aperture, wherein when the first front gusset wall aperture and the first rear gusset wall aperture align, a first portion of the front wall is sealed to a first portion of the rear wall through the aligned first front and rear gusset wall apertures; and wherein the second front gusset wall includes a second front gusset wall aperture and the second rear gusset wall includes a second rear gusset wall aperture, wherein when the second front gusset wall aperture and the second rear gusset wall aperture align, a second portion of the front wall is sealed to a second portion of the rear wall through the aligned second front and rear gusset wall apertures.
 2. The reclosable package or bag of claim 1 wherein the first and second portions of the front wall are sealed to the respective first and second portions of the rear wall by conduction or ultrasonic heat sealing.
 3. The reclosable package or bag of claim 1 wherein the first and second portions of the front wall are sealed to the respective first and second portions of the rear wall by adhesive.
 4. The reclosable package or bag of claim 1 wherein the gusset wall apertures are formed in an area of the front and rear gusset walls proximate to the reclosable zipper.
 5. The reclosable package or bag of claim 1 wherein the first front gusset wall and the first rear gusset wall form a first inwardly pointing V-shape and the second front gusset wall and the second rear gusset wall form a second inwardly pointing V-shape.
 6. The reclosable package or bag of claim 1 wherein the gusset walls are formed of a same material as the front wall and the rear wall.
 7. The reclosable package or bag of claim 1 wherein the gusset walls are formed integrally with the front wall and the rear wall.
 8. The reclosable package or bag of claim 1 wherein the reclosable zipper includes a first profile attached to the front wall, a second profile attached to the rear wall, and a slider to interlock the first and second profiles when moved in a first direction and to separate the first and second profiles when moved in a second direction.
 9. A reclosable package or bag comprising: a front wall including a first front wall aperture and a second front wall aperture; a rear wall including a first rear wall aperture and a second rear wall aperture; a first gusset formed between a first edge of the front wall and a first edge of the rear wall, the first gusset including a first front gusset wall and a first rear gusset wall; a second gusset formed between a second edge of the front wall and a second edge of the rear wall, the second gusset including a second front gusset wall and a second rear gusset wall; a mouth formed between a top edge of the front wall and a top edge of the rear wall; a reclosable zipper including a first flange secured to the front wall and a second flange secured to the rear wall proximate to the mouth; and wherein the first front gusset wall includes a first front gusset wall aperture and the first rear gusset wall includes a first rear gusset wall aperture, wherein when the first front gusset wall aperture, the first rear gusset wall aperture, the first front wall aperture and the first rear wall aperture align, a first portion of the first flange is sealed to a first portion of the second flange through the aligned first front and rear gusset wall apertures and the first front and rear wall apertures; and wherein the second front gusset wall includes a second front gusset wall aperture and the second rear gusset wall includes a second rear gusset wall aperture, wherein when the second front gusset wall aperture, the second rear gusset wall aperture, the second front wall aperture and the second rear wall aperture align, a second portion of the first flange is sealed to a second portion of the second flange through the aligned second front and rear gusset wall apertures and the second front and rear wall apertures.
 10. The reclosable package or bag of claim 9 wherein the first and second portions of the first flange are sealed to the respective first and second portions of the second flange by conduction or ultrasonic heat sealing.
 11. The reclosable package or bag of claim 9 wherein the first and second portions of the front wall are sealed to the respective first and second portions of the rear wall by adhesive.
 12. The reclosable package or bag of claim 9 wherein the gusset wall apertures and the wall apertures are formed in an area of the gussets and the walls, respectively, proximate to the reclosable zipper.
 13. The reclosable package or bag of claim 9 wherein the first front gusset wall and the first rear gusset wall form a first inwardly pointing V-shape and the second front gusset wall and the second rear gusset wall form a second inwardly pointing V-shape.
 14. The reclosable package or bag of claim 9 wherein the gusset walls are formed of a same material as the front wall and the rear wall.
 15. The reclosable package or bag of claim 9 wherein the gusset walls are formed integrally with the front wall and the rear wall.
 16. The reclosable package or bag of claim 9 wherein the reclosable zipper includes a first profile including the first flange, a second profile including the second flange, and a slider to interlock the first and second profiles when moved in a first direction and to separate the first and second profiles when moved in a second direction.
 17. A reclosable package or bag comprising: a front wall and a rear wall; a first gusset formed between a first edge of the front wall and a first edge of the rear wall; a second gusset formed between a second edge of the front wall and a second edge of the rear wall; a mouth formed between a top edge of the front wall and a top edge of the rear wall; a reclosable zipper secured to the front and rear walls proximate to the mouth; a first stitch joining a first portion of the front wall, the first front gusset wall, the first rear gusset wall and a first portion of the rear wall; and a second stitch joining a second portion of the front wall, the second front gusset wall, the second rear gusset wall and a second portion of the rear wall.
 18. The reclosable package or bag of claim 17 wherein the first and second stitches are formed from thread.
 19. The reclosable package or bag of claim 17 wherein the first front gusset wall and the first rear gusset wall form a first inwardly pointing V-shape and the second front gusset wall and the second rear gusset wall form a second inwardly pointing V-shape.
 20. The reclosable package or bag of claim 17 wherein the reclosable zipper includes a first profile attached to the front wall, a second profile attached to the second wall, and a slider to interlock the first and second profiles when moved in a first direction and to separate the first and second profiles when moved in a second direction. 